Patents by Inventor Paul R. Faughnan

Paul R. Faughnan has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20200384607
    Abstract: A method for deep roll peening a workpiece includes deep roll peening a workpiece by moving the workpiece along a feed path through multiple groups of opposed rollers that are arranged in series. Each group of opposed rollers includes a rim that defines a workpiece engagement surface that exerts a deep roll peening force on the workpiece. A deep roll peening system includes multiple groups of opposed rollers. Each of the opposed rollers is rotatably mounted and has a rim that defines a workpiece engagement surface. The workpiece engagement surfaces are spaced apart from each other by a gap. The groups are arranged in series such that the gaps define a feed path for receiving a workpiece into serial contact with the workpiece engagement surfaces.
    Type: Application
    Filed: March 30, 2020
    Publication date: December 10, 2020
    Inventors: Andrzej Ernest Kuczek, Joseph C. Rampone, Tahany Ibrahim El-Wardany, Paul R. Faughnan, JR.
  • Publication number: 20200108458
    Abstract: A method of forming a gas turbine engine component including an airfoil and at least one shroud includes the steps of (1) machining a gas path surface of the at least one shroud utilizing a non-electrochemical machining (ECM) process, and (2) then utilizing ECM on at least the airfoil.
    Type: Application
    Filed: March 1, 2019
    Publication date: April 9, 2020
    Inventors: Alex C. Freedman, Paul R. Faughnan
  • Patent number: 10603761
    Abstract: A method for deep roll peening a workpiece includes deep roll peening a workpiece by moving the workpiece along a feed path through multiple groups of opposed rollers that are arranged in series. Each group of opposed rollers includes a rim that defines a workpiece engagement surface that exerts a deep roll peening force on the workpiece. A deep roll peening system includes multiple groups of opposed rollers. Each of the opposed rollers is rotatably mounted and has a rim that defines a workpiece engagement surface. The workpiece engagement surfaces are spaced apart from each other by a gap. The groups are arranged in series such that the gaps define a feed path for receiving a workpiece into serial contact with the workpiece engagement surfaces.
    Type: Grant
    Filed: June 6, 2016
    Date of Patent: March 31, 2020
    Assignee: UNITED TECHNOLOGIES CORPORATION
    Inventors: Andrzej Ernest Kuczek, Joseph C. Rampone, Tahany Ibrahim El-Wardany, Paul R. Faughnan, Jr.
  • Publication number: 20180010484
    Abstract: A method for producing a diffusion cooling hole extending between a wall having a first wall surface and a second wall surface includes forming a cooling hole inlet at the first wall surface, forming a cooling hole outlet at the second wall surface, forming a metering section downstream from the inlet and forming a multi-lobed diffusing section between the metering section and the outlet. The inlet, outlet, metering section and multi-lobed diffusing section are formed by laser drilling, particle beam machining, fluid jet guided laser machining, mechanical machining, masking and combinations thereof.
    Type: Application
    Filed: February 3, 2017
    Publication date: January 11, 2018
    Inventors: Gordon Miller Reed, Paul R. Faughnan, JR., John Quitter
  • Publication number: 20170348821
    Abstract: A method for deep roll peening a workpiece includes deep roll peening a workpiece by moving the workpiece along a feed path through multiple groups of opposed rollers that are arranged in series. Each group of opposed rollers includes a rim that defines a workpiece engagement surface that exerts a deep roll peening force on the workpiece. A deep roll peening system includes multiple groups of opposed rollers. Each of the opposed rollers is rotatably mounted and has a rim that defines a workpiece engagement surface. The workpiece engagement surfaces are spaced apart from each other by a gap. The groups are arranged in series such that the gaps define a feed path for receiving a workpiece into serial contact with the workpiece engagement surfaces.
    Type: Application
    Filed: June 6, 2016
    Publication date: December 7, 2017
    Inventors: Andrzej Ernest Kuczek, Joseph C. Rampone, Tahany Ibrahim El-Wardany, Paul R. Faughnan, JR.
  • Patent number: 9598979
    Abstract: A method for producing a diffusion cooling hole extending between a wall having a first wall surface and a second wall surface includes forming a cooling hole inlet at the first wall surface, forming a cooling hole outlet at the second wall surface, forming a metering section downstream from the inlet and forming a multi-lobed diffusing section between the metering section and the outlet. The inlet, outlet, metering section and multi-lobed diffusing section are formed by laser drilling, particle beam machining, fluid jet guided laser machining, mechanical machining, masking and combinations thereof.
    Type: Grant
    Filed: July 9, 2012
    Date of Patent: March 21, 2017
    Assignee: United Technologies Corporation
    Inventors: Gordon Miller Reed, Paul R. Faughnan, Jr., John Quitter
  • Publication number: 20160024942
    Abstract: An article (104;140) has an airfoil (100). The airfoil has a leading edge (114), a trailing (116) edge, a pressure side (118), and a suction side (120) and the airfoil extends from a first end (110) to a tip (112). The article comprises an aluminum alloy or titanium alloy substrate (352) and a coating at the tip. The coating comprises a cold sprayed nickel or cobalt matrix (352) and an abrasive (354).
    Type: Application
    Filed: December 3, 2013
    Publication date: January 28, 2016
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Paul R. Faughnan, JR., Aaron T. Nardi, Michael A. Klecka
  • Publication number: 20160003083
    Abstract: An abradable seal for a gas turbine engine includes a seal body that has a seal side and a non-seal side. The seal body includes an abradability characteristic that varies by locality.
    Type: Application
    Filed: January 27, 2014
    Publication date: January 7, 2016
    Inventors: Robert P. Delisle, Paul R. Faughnan, JR., Christopher F. O'Neill, Jesse R. Boyer
  • Publication number: 20140170012
    Abstract: The invention relates to an additive manufacturing apparatus and method. According to the invention, an additive manufacturing apparatus includes a material supply system. The material supply system delivers layers of partially sintered pulverant material to an additive manufacturing device.
    Type: Application
    Filed: December 18, 2012
    Publication date: June 19, 2014
    Applicant: United Technologies Corporation
    Inventors: Robert P. Delisle, Christopher F. O'Neill, Paul R. Faughnan, Jesse R. Boyer
  • Publication number: 20130206739
    Abstract: A method for producing a diffusion cooling hole extending between a wall having a first wall surface and a second wall surface includes forming a cooling hole inlet at the first wall surface, forming a cooling hole outlet at the second wall surface, forming a metering section downstream from the inlet and forming a multi-lobed diffusing section between the metering section and the outlet. The inlet, outlet, metering section and multi-lobed diffusing section are formed by laser drilling, particle beam machining, fluid jet guided laser machining, mechanical machining, masking and combinations thereof.
    Type: Application
    Filed: July 9, 2012
    Publication date: August 15, 2013
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Gordon Miller Reed, Paul R. Faughnan, JR., John Quitter
  • Publication number: 20130116817
    Abstract: A method for machining and inspecting a workpiece includes steps of: supporting the workpiece with a workpiece support; moving a machining tool relative to the workpiece with a tool positioning system, and machining a workpiece feature into the workpiece with the machining tool as a function of reference geometry data; moving a measuring device relative to the workpiece with a measuring device positioning system that is independent of the tool positioning system, and mapping a geometry of the workpiece feature with the measuring tool to provide workpiece geometry data indicative thereof; and processing the workpiece geometry data and the reference geometry data with a processor to compare the geometry of the workpiece feature to a reference geometry.
    Type: Application
    Filed: November 4, 2011
    Publication date: May 9, 2013
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Paul R. Faughnan, JR., Edward Marchitto, Jesse R. Boyer
  • Patent number: 7967659
    Abstract: A method of manufacturing an integral bladed rotor is disclosed. The method includes calculating a cutting path in an area of a blank between adjacent blade locations to approximate contours of adjacent blades. A cutter is plunged into the area at an initial angle and depth that extends from an outer perimeter to the blank to an inner perimeter of the blank, in one example. The blade roots extend from the inner perimeter, and the blade tips terminate near the outer perimeter. The cutter is plunged into the area at an original angle that, in one example, is different than the initial angle. The cutter is rotated about an axis in a spiral-like fashion as the cutter extends further into the blank, along the cutting path.
    Type: Grant
    Filed: May 15, 2008
    Date of Patent: June 28, 2011
    Assignee: United Technologies Corporation
    Inventors: Robert E. Erickson, Paul R. Faughnan, Jr.
  • Publication number: 20090285647
    Abstract: A method of manufacturing an integral bladed rotor is disclosed. The method includes calculating a cutting path in an area of a blank between adjacent blade locations to approximate contours of adjacent blades. A cutter is plunged into the area at an initial angle and depth that extends from an outer perimeter to the blank to an inner perimeter of the blank, in one example. The blade roots extend from the inner perimeter, and the blade tips terminate near the outer perimeter. The cutter is plunged into the area at an original angle that, in one example, is different than the initial angle. The cutter is rotated about an axis in a spiral-like fashion as the cutter extends further into the blank, along the cutting path.
    Type: Application
    Filed: May 15, 2008
    Publication date: November 19, 2009
    Inventors: Robert E. Erickson, Paul R. Faughnan, JR.
  • Publication number: 20090094831
    Abstract: An integrally bladed rotor includes a central hub and a plurality of airfoils or blades. The blades are repaired by rebuilding their surfaces beyond the original shape, such as by adding weld material. The contour of the blade is then returned to the desired shape using superabrasive quills.
    Type: Application
    Filed: October 16, 2007
    Publication date: April 16, 2009
    Inventors: Brian J. Schwartz, Robert E. Erickson, Paul R. Faughnan, JR., Bernard D. Vaillette